Tubular component for an aerosol-generating article and a method of manufacture

Abstract

A method of manufacturing a tubular component for an aerosol-generating article for use in a non-combustible aerosol delivery system is disclosed. The method comprises applying a flexible body of material to a layer of wrapping material and subsequently forming the layer, together with the body of material applied thereto, into a tubular component in which the body of material is encircled by the layer of wrapping material. A tubular component for an aerosol-generating article for use in a non-combustible aerosol-provision system, an article for use in a non-combustible aerosol provision system that includes an aerosol-generating device, and a system comprising a non- combustible aerosol generating device are also disclosed.

Description

[0001] Tubular Component for an Aerosol-Generating Article and a Method of Manufacture

[0002] The present invention relates to a method of manufacturing a tubular component for an aerosol-generating article for use in a non-combustible aerosol-provision system. The invention also relates to a tubular component for an aerosol-generating article for use in a non-combustible aerosol provision system, to an aerosol-generating article for use in a non-combustible aerosol provision system that includes an aerosol-generating device, and to a system comprising a non-combustible aerosol generating device and an aerosol-generating article.

[0003] Background

[0004] Certain tobacco industry products produce an aerosol which is inhaled by a user during use. For example, tobacco heating devices heat an aerosol generating substrate such as tobacco to form an aerosol by heating, but not burning, the substrate. Such tobacco industry products commonly include mouthpieces through which the aerosol passes to reach the user’s mouth.

[0005] Summary In accordance with some embodiments described herein, there is provided a method of manufacturing a tubular component for an aerosol-generating article for use in a non- combustible aerosol delivery system, comprising applying a flexible body of material to a layer of wrapping material and subsequ ently forming the layer, together with the body of material applied thereto, into a tubular component in which the body of material is encircled by the layer of wrapping material.

[0006] The body of material may be applied to said layer whilst said layer is substantially planar. The body of material may be applied to the layer to a thickness greater than the thickness of the layer.

[0007] The method may comprise forming the layer, together with the body of material applied thereto, into a tubular component by wrapping said layer, together with the body of material applied thereto, around a cylindrical mandrel. The method of forming the layer, together with the body of material applied thereto, into a tubular component may comprise applying adhesive to the layer so that edges of the layer that come into contact when the layer is wrapped around a cylindrical mandrel bond to each other.

[0008] The body of material may be attached to the layer with adhesive.

[0009] In some embodiments, the body of material can be non-woven cellulose so that the method comprises applying non-woven cellulose to the layer.

[0010] In other embodiments, the body of material can be paper, so that the method comprises applying said paper to the layer. The paper maybe crimped or corrugated prior to application to the layer.

[0011] The body of material may be applied to the layer of wrapping material in layers. The body of material may be pre-formed as a laminate structure prior to application to the layer. Alternatively, the layers maybe applied to the layer of wrapping material consecutively. The layers may be to each other with adhesive.

[0012] In some embodiments, the method may comprise applying the body of material to the layer of wrapping material in liquid, or other non-solid phase, form and allowing i t to set prior to forming the layer, and the body of material applied thereto, into a tubular component. Application of the body of material in liquid form may comprise spraying, coating or printing onto the layer.

[0013] In some embodiments, the method may comprise applying the body of material to the layer in spaced elongate strips or lines so that, when the layer and the body of material applied thereto is formed into a tubular component, the elongate strips or lines extend in a longitudinal direction parallel to a longitudinal axis of the tubular component.

[0014] The appli cation of the body of material in spaced elongate strips or lines may be such that a gap remains between each strip when the layer, together with the body material applied thereto, is formed into a tubular component.

[0015] In alternate embodiments, the body of material may be applied to the layer such that it extends continuously across the layer. The material may extend across the layer of wrapping material to a uniform thickness. Alternatively, the body of material maybe applied so that its thickness varies in a direction extending across the layer. The thickness may vary according to a defined pattern, i.e. the body of material may have a corrugated profile. Alternatively, the thickness of the body of material may be irregular across the layer of wrapping materi al.

[0016] The method may include the step of forming an elongate rod by wrapping the layer, together with the body of material applied thereto, around a mandrel and subsequently cutting the rod at spaced apart intervals to form a plurality of indi vidual tubular components.

[0017] In accordance with another embodiment described herein, there is provided a tubular component for an aerosol-generating article for use in a non-combustible aerosol- provision system, the tubular component having a longitudinal axis and comprising a body of material encircled by an outer layer of wrapping material, wherein the body of material comprises multiple layers.

[0018] At least one layer of the body of material may be formed from a non-woven material such as cellulose.

[0019] At least one layer of the multiple layers maybe formed from paper. The paper can be crimped and formed from strips. Alternatively, the paper may have a corrugated profile. The layers, or some of the layers, can be attached to each other with adhesive.

[0020] Two or more of the multiple layers can be formed from the same or different materials.

[0021] The outer layer of wrapping material may be formed from paper.

[0022] The tubular component may further comprise an inner layer that lines the body of material. The inner layer maybe formed from the same material as the outer layer.

[0023] In accordance with another embodiment described herein, there is provided a tubular component for an aerosol-generating article for use in a non-combustible aerosol- provision system, the tubular component having a longitudinal axis and comprising a body of material encircled by an outer layer of wrapping m aterial, wherein the body of material comprises a plurality of longitudinally extending circumferentially spaced strips each of which extend radially inward towards the longitudinal axis. Each strip may extend parallel to said longitudinal axis.

[0024] Each strip may narrow in a radially inward direction towards the longitudinal axis and terminate in a tip. Each strip can be shaped so that an edge of a strip, that extends between the outer layer of wrapping material and the tip, is parallel to a facing edge of an adjacent strip.

[0025] The tip of each strip may be radially closer to the longitudinal axis than to said outer sheet.

[0026] The tip of each strip may comprise a surface that extends circumferentially about the longitudinal axis.

[0027] The surface forming the tip may be arcuate and the axis of curvature of each surface may be coaxial with the longitudinal axis of the tubular component.

[0028] In accordance with another embodiment described herein, there is provided article for use in a non-combustible aerosol provision system that includes an aerosol-generating device, the article comprising a hollow tubular component made according to the method of the invention.

[0029] In accordance with another embodiment described herein, there is provided an article for use in a non-combustible aerosol provision system that includes an aerosol generating device, the article comprising a tubular component according to the invention.

[0030] In accordance with another embodiment described herein, there is provided a system comprising a non-combustible aerosol generating device comprising a heating element, an aerosol-generating article according to the invention.

[0031] Brief Description of the Drawings Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0032] Figure 1 is a side-on cross-sectional view of an aerosol-generating article for use with a non-combustible aerosol provision device, according to an embodiment of the invention;

[0033] Figure 2a shows a cross-section through a hollow tubular component of the aerosol- generating article of Figure 1, taken along line A- A, according to a first embodiment of the invention:

[0034] Figure 2b shows the outer sheet of the hollow tubul ar compon ent of Figure 2a to which the body of material has been applied and prior to the outer sheet being formed, together with the body of material, into a tubular component;

[0035] Figu re 3a shows a cross-section through a hollow tubular component of the aerosol- generating article of Figure 1, taken along line A- A, according to a second embodiment of the invention; Figu re 3b shows the outer sheet of the hollow tubular component of Figure 3a to which the body of material has been applied and prior to the outer sheet being formed, together with the body of material, into a tubular component;

[0036] Figure 4a shows a cross-section through a hollow tubular component of the aerosol- generating article of Figure 1, taken along line A- A, according to a third embodiment of the invention;

[0037] Figure 4b shows the outer sheet of the hollow tubular component of Figure 4a to which the body of material has been applied and prior to the outer sheet being formed, together with the body of material, into a tubular component;

[0038] Figure 5 is a simplified cross-sectional view of a non-combustible aerosol provision system comprising an aerosol provision device with an aerosol-generating article, as shown in any of Figures 1 to 4, inserted into it; and

[0039] Figure 6 is a simplified schematic of the components of the aerosol provision device shown in Figure 5. Detailed Description

[0040] As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol -free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

[0041] According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned to facilitate delivery of at least one substance to a user.

[0042] In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

[0043] In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0044] In some embodiments, the non-combustible aerosol provision system is an aerosol- generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

[0045] In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine.

[0046] In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product. Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device, and a consumable for use with the non- combustible aerosol provision device. An embodiment of the disclosure relates to a component that forms part of a consumable comprising aerosol-generating material and which is configured to be used with a non-combustible aerosol provision device. The consumable is sometimes referred to as an article throughout the disclosure. The disclosure also relates to a consumable or article comprising the component, and to a system comprising the device and the article.

[0047] The terms ‘upstream’ and ‘downstream’ used herein are relative terms defined in relation to the direction of mainstream aerosol drawn through an article in use. Reference to the ‘distal end’ (D) refers to an upstream end of the device, whereas ‘proximal end’ (P) refers to the downstream end of the device.

[0048] In some embodiments, the non-combustible aerosol provision system, particularly the non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source. In some embodiments, the non-combustible aerosol provision device comprises an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and / or an aerosol-modifying agent.

[0049] In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent. The consumable comprises a substance to be delivered. The substance to be delivered is an aerosol-generating material. As appropriate, the material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and / or one or more other functional materials.

[0050] In some embodiments, the substance to be delivered comprises an active substance. The acti ve substance as used herein may be a physiologically active material , which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance maybe naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical. In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

[0051] As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material maybe in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crlspa, Mentha cardifolia, Memtha longlfolla, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

[0052] In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

[0053] In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

[0054] In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel. In some embodiments, the substance to be delivered comprises a flavour.

[0055] As used herein, the terms "flavour" and "flavour ant" refer to materials which, where local regulations permit, maybe used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, beriy, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang- ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas. In some embodiments, the flavour comprises menthol, spearmint and / or peppermint.

[0056] In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and / or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

[0057] In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3. An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. An aerosol-generating material may be in the form of a solid, liquid or gel w’hich may or may not contain an active substance and / or flavourants. The aerosol-generating material is incorporated into an article for use in the aerosol-generating system.

[0058] As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material maybe in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and / or tobacco extract. A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, in particular a heating element, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, comprise, a material heatable by electrical conduction, or a susceptor. An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavou r, acidity or another characteristic of the aerosol. The aerosol- modifying agent maybe provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.

[0059] The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent maybe in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

[0060] An aerosol-generating device is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. The aerosol generating device comprises a heater configured to subject the aerosol-generating material to heat energy to release one or more volatiles from the aerosol-generating material to form an aerosol.

[0061] The filamentary tow material described herein can comprise cellulose acetate fibre tow. The filamentary tow can also be formed using other materials used to form fibres, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), polyfbutylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof. The filamentary tow may be plasticised with a suitable plasticiser for the tow, such as triacetin where the material is cellulose acetate tow, or the tow may be non-plasticised. The tow can have any suitable specification, such as fibres having a Y shaped or other cross section such as ‘X’ shaped, filamentary denier values between 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament and total denier values of 5,000 to 50,000, for example between 10,000 and 40,000. In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components.

[0062] Figure 1 is a longitudinal cross-sectional view of an aerosol-generating article 1 that forms part of an aerosol delivery system that includes an aerosol delivery device 100 (see Figures 5 and 6).

[0063] The article 1 has an upstream or distal end ‘D’ and a downstream or proximal end ‘P’ and a longitudinal axis X-X. The proximal end P comprises a mouthpiece 2, which may comprise cellulose acetate filter material and can contain capsule 3 containing an aerosol-modifying agent or liquid flavourant. In alternate embodiments, the mouthpiece 2 maybe a hollow tubular element and / or the capsule 3 maybe omitted. An aerosol-generating section 4 is connected to the mouthpiece 2. In the present example, the aerosol generating section 4 comprises a rod of aerosol-generating material 5. The aerosol -generating material 5 may comprise a plurality of strands or strips of aerosol-generating material 5 and is circumscribed by a wrapper 6 that can include one or more layers. The wrapper 6, or one of the layers of the wrapper 6, may be aluminium foil. In other embodiments, the wrapper 6 can be made of one or more paper layers optionally comprising a barrier coating to make the material of the wrapper 6 substantially moisture impermeable.

[0064] The aerosol-generating section 4 includes a cooling element 7, positioned downstream of the aerosol-generating material 5 and in abutting relation to the mouthpiece 2. The cooling element 7 comprises a hollow channel 8, having an internal diameter of between about 1 mm and about 4 mm, for example between about 2 mm and about 4 mm. In the present example, the hollow channel 8 has an internal diameter of about 3 mm. The hollow channel 8 exte nds along the full length of the cooling ele ment 7. The hollow channel 8 provides a space into which aerosol drawn into the cooling element 7 from the rod of aerosol generating material 5 expands and cools down. The cooling element 7 can be configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first, upstream end (D) of the cooling element 7 and a heated volatilised component exiting a second, downstream end (P) of the cooling element 7. Ventilation is provided directly into the cooling element 7 via at least one row of perforations 9 extending through the outer wall.

[0065] The cooling element 7 has a wall thickness in a radial direction. The wall thickness of the cooling element 7, for a given outer diameter, defines the internal diameter for the channel 8 surrounded by the walls of the cooling element 7. The cooling element 7 has a wall thickness of at least about 1.5 mm and up to about 2 mm. In the present example, the cooling element 7 has a wall thickness of about 2 mm. The cooling element 7 may be formed from filamentary tow. The wall material of the cooling element 7 can be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol generating material 5 passes longitudinally through the channel 8 of the cooling element 7 rather than through the wall material of the cooling element 7. For instance, at least 92% or at least 95% of the aerosol generated by the aerosol generating material 3 passes longitudinally through the hollow channel 8.

[0066] As shown in Figure 1, the article 1 may comprise a plug 10 at the distal end D. In this embodiment, the heating element is inserted into the aerosol-generating material 5 through the plug 10. In the embodiment of Figure 1, the plug 10 is tubular, although it may also be a cylindrical solid element.

[0067] In embodiments of the inven tion, a tubular component 11 is positioned between the aerosol generating material 5 and the cooling element 7. The tubular component 11 is hollow and comprises a body of material 12 that is encircled by an outer layer of wrapping material 13 which maybe plug wrap or other wrapper. The tubular component 11 has a radial wall thickness that is greater relative to the radial wall- thickness of the cooling element 7. For example, the wall thickness of the tubular component 11 can be in the order of 3.5 to 4mm. The tubular component 11 is also shorter that the cooling element 7 and may have a typical length of around 7mm. Due to its increased wall thickness relative to the wall thickness of the cooling element 7, the tubular component 11 is a structural element of the aerosol-generating article 1 and provides the aerosol-generating article 1 with improved rigidity that makes it more able to withstand the axial compressive forces and bending moments that arise during manufacture and whilst the article 1 is in use. Further, as the tubular component 11 is hollow, it doesn’t impede the flow of aerosol therethrough compared to the flow through a solid cylindrical filter element. The increased wall thickness also makes the tubular component 11 more resilient and able to withstand moisture ingress for longer without collapsing or buckling.

[0068] A cross-sectional view’ through the tubular component 11 according to one embodiment of the invention, and which is taken along the line A-A of Figure 1, is shown in Figure

[0069] 2a. In this embodiment, the body of material 12 comprises a plurality of identical, circumferentially spaced elongate strips or lines 12a of material that extend along the length of the hollow tubular component 11 parallel to the longitudinal axis X-X (See Figure 1). Each strip is equally spaced in a circumferential direction about the axis X-X and extends in a radially inward direction from an inner surface of the outer sheet towards the longitudinal axis X-X of the component. One or more of the strips 12a can have different cross-sectional shapes but, as shown in Figure 2a, each strip 12a is the same and narrow's or tapers in a radially inward direction towards the longitudinal axis X-X. Each strip terminates in a tip 14 spaced from the longitudinal axis X-X which can be closer to the longitudinal axis X-X than to the sheet 13. The tip 14 of each strip 12a may be shaped so that the edge 15 of each strip 12a, that extends between an inner surface of the sheet 13 and the tip 14, is spaced from but parallel to a facing edge of an adjacent strip 12a. In another embodiment, the edges 15 of adjacent strips 12a, or at least a portion of the edges of adjacent strips 12a, maybe in contact with each other. The tip 14 of each strip 12a may comprise a surface that extends in a circumferential direction about the longitudinal axis X-X. The surface maybe arcuate and have a radius of curvature centered coaxially with the longitudinal axis X-X.

[0070] Each strip 12a maybe formed from multiple layers of paper or a paper laminate, from a foam material, from one or more layers of non-woven cellulose or from a combination of these or of different non-woven sheet-like material layers. A method of manufacturing the tubular element 11 using these or other materials is described in more detail below. The use of paper-based and / or cellulose material in the construction of the tubular component avoids the use of plastic materials, and particularly single-use plastics materials. This has the advantage of making the tubular element recyclable or compostable. It also reduces the weight of the tubular component and aerosol- generating article of which the tubular component forms a part. A cross-sectional view through a tubular component 11 according to another embodiment of the invention taken along the line A-A in Figure 1, is shown in Figure 3a. In this embodiment, the body of material 12 has an annular cross-section and is tubular in shape. The body of material 12 extends along the length of the tubular component 11. The body of material 12 may be formed from multiple layers of material, as with the strips 12a described above with reference to Figure 2a. The multiple layers maybe applied to the layer of wrapping material 13 consecutively. In any embodiments of the invention, the body of material may be formed of regenerated cellulose. A cross-sectional view through a tubular component 11 according to another embodiment of the invention taken along the line A-A in Figure 1, is shown in Figure 4a. In this embodiment, the body of material 12 has a tubular cross-section and extends along the length of the tubular component 11, but its inner surface that faces toward the longitudinal axis X-X is irregular in shape. The body of material 12 may be formed of paper, or layers of paper. The paper, or at least some of the layers of paper, can be crimped or corrugated . The inner surface 12b of the body of material 12 may have a regular or irregular pattern extending circumferentially about the longitudinal axis X- X. In any of the tubular components 11 according to embodiments of the invention, there may be an inner layer or sheet (not shown) that lines the body of material 12. The inner layer or sheet maybe tubular. The inner and outer sheets may both be coaxial with the longitudinal axis of the aerosol-generating article. Tipping paper (not shown) may be wrapped around the full length of the mouthpiece 2 and the aerosol-generating section, over the wrapper 4, to connect the mouthpiece 2 to the aerosol-generating section.

[0071] A non-combustible aerosol provision system 15 comprising a device 16 and an aerosol generating article 1 received in the device 16, is shown in a simplified manner in Figure

[0072] 5. As shown, the non-combustible aerosol provision device 16 has a housing 17 comprising a recess 18 in which is received the aerosol-generating article 1 and in which a heater 19 is inserted into the aerosol generating material of the article 1. As shown in Figure 6, within the housing 17 there is an electrical energy supply 20, for example a rechargeable lithium-ion battery. A controller 21 is connected to the heater 19, the electrical energy supply 20, and a user interface 22, for example a button or display. The controller 21 controls the power supplied to the heater 19 to regulate its temperature. Typically, the aerosol-forming substrate 5 is heated to a temperature of between 250 and 450 degrees centigrade.

[0073] A method of manufacturing a tubular component 11 according to embodiments of the invention will now be described. Figure 2b shows a section of sheet of material 13 to which the body of material 12 has been applied in the form of spaced, parallel elongate strips or lines prior to it being formed into the tubular component 11 shown in Figure 2a, and which can be achieved by wrapping it about longitudinal axis X-X. It will be appreciated that only a short length of the layer of wrapping material 13 is shown in Figure 2b, and that the layer 13 may extend continuously in the longitudinal direction, i.e. it maybe fed from a reel or bobbin (not shown) which is used to form an elongate tubular rod which is then subsequently cut into individual tubular components 11 by severing the rod at right angles to the longitudinal axis X-X at repeated intervals.

[0074] The method according to embodiments of the invention comprises applying the body of material 12 to a portion or whole surface of the layer of wrapping material 13 prior to forming the layer 13, together with the body of material 12 applied thereto, into a tubular component 11. The material 12 may be sprayed or laid or otherwise coated onto the layer 13 whilst the layer 13 remains in a planar or flat configuration, or it maybe applied as the layer 13 is being manipulated into a tubular form, i.e. it may be applied as the layer 13 has assumed a curved cross-sectional profile but before a tubular shape has been fully formed . If the body of material 12 is sprayed or coated onto the surface of the layer 13, then the body of material 12 may be allowed to cure before the layer 13, together with the body of material 12 applied thereto is formed into a tubular component 11.

[0075] In some circumstances, an adhesive may be used to bond the body of material 12 to the layer 13. The adhesive may be applied to the layei’13 prior to application of the body of material 12. The body of material 12 maybe applied to a required thickness in one or multiple applications to the surface of the layer 13. For example, the body of material 12 can be made up of layers, each layer being applied to the layer of wrapping material 13 consecutively. Each layer can be attached to a previously applied layer using adhesive. The or each layer that forms the body of material can be formed from non-woven sheet- like material such as paper, or in the form of a fibrous tow, such as cellulose. In certain applications it may be appropriate to use layers formed from different materials. For example, one layer may be formed from non-woven cellulose and another layer may be formed from paper. Irrespective of whether paper is used in combination with any other material or layer, the paper may be crimped and / or formed from strips, or the paper may have a corrugated or other irregular shaped profile. If the body of material is applied in strip form, as described with reference to Figure 2a, adjacent strips 12a may be formed of a different material .

[0076] A nonwoven sheet-like material or fibrous tow typically comprises a plurality of fibers therein. In some embodiments, filter materials according to the disclosure (either in the form of a nonwoven sheet or a fibrous tow) maybe formed of alternative or recycled fiber materials. Such alternative fibers materials may beneficially provide increased biodegradability and / or reduced plasticity when compared to the types of fiber inputs used in conventional cigarette filters, e.g., such as cellulose acetate. In some embodiments, the body of material prepared according to the present disclosure may comprise a plurality of fibers selected from the group consisting of regenerated cellulose, hemp, sisal, kenaf, esparto, jute, flax, wood, reconstituted tobacco, and combinations thereof. As used herein, the term “fiber” is defined as a basic element of textiles. It should be noted that the body of material of the present disclosure may include any of the noted fiber inputs individually or in combination with one or more other fiber inputs. Fibers are often in the form of a rope- or string-like element. As used herein, the term “fiber” is intended to include fibers, filaments, continuous filaments, staple fibers, and the like.

[0077] In some embodiments, the body of material as described herein may comprise regenerated cellulose fibers, in particular. It should be noted that the body of material may comprise solely regenerated cellulose fibers or the regenerated cellulose fibers may be combined with one or more other fiber inputs as described herein. Regenerated cellulose fibers are typically prepared by extracting non-cellulosic compounds from wood, contacting the extracted wood with caustic soda, followed by carbon disulfide and then by sodium hydroxide, giving a viscous solution. The solution is subsequently forced through spinneret heads to create viscous threads of regenerated fibers. Exemplary methods for the preparation of regenerated cellulose are provided in U.S. Pat. No. 4,237,274 to Leoni et al; U.S. Pat. No. 4,268,666 to Baldini et al; U.S. Pat. No. 4,252,766 to Baldini et al.; U.S. Pat. No. 4,388,256 to Ishida et al.; U.S. Pat. No.

[0078] 4,535,028 to Yokogi et al.; U.S. Pat. No. 5,441,689 to Laity; U.S. Pat. No. 5,997,790 to Vos et al.; and U.S. Pat. No. 8,177,938 to Sumnicht, which are incorporated herein by reference. The way in which the regenerated cellulose is made is not limiting, and can include, for example, both the rayon and the TENCEL processes. Various suppliers of regenerated cellulose are known, including Lenzing (Austria), Cordenka (Germany), Aditya Birla (India), and Daicel (Japan). Examples of regenerated cellulose fibers include, but are not limited to, rayon, viscose, viscose rayon, lyocell, and the like. To form the layer of wrapping materiali3, and the body of material 12 applied thereto, into a tubular component 11, it maybe drawn over and wrapped around a cylindrically shaped mandrel (not shown). In certain embodiments, the layer 13, and the body of material 12 applied thereto may be wrapped around a mandrel in helical fashion. The layer 13 may have an edge 13a to which no body of material 12 is applied and which overlaps anoth er edge of the layer 13 when the layer 13 and the body of material 12 applied thereto has been formed into a tubular component 11. Adhesive may be applied to the edge 13a so that it bonds to the layer in overlapping regions, thereby holding the component 11 in its tubular form after it has been wrapped around and extracted from the end of the m andrel.

[0079] The method of forming the hollow tubular component 11 of Figure 3a is similar to the method described above with reference to Figure 2b, except that a single wide strip of m aterial 12 is applied to the layer of wrapping m aterial 13 in one or more layers. As with the embodiment of Figure 2b, the hollow tubular componen t 11 is formed by wrapping the layeri3, to which the body of material 12 has been applied, around a cylindrical mandrel to form a hollow elongate rod which is then cut at spaced intervals to form a plurality of hollow tubular components 11.

[0080] The method of forming the hollow tubular component 11 of Figure 4a is similar to the method described above with reference to Figure 2b, except that the body of material 12 applied to the layer 13 is corrugated or crimped or otherwise has an irregular shaped profile. The material 12 maybe applied in layers. The first layer which is in contact with the sheet maybe bonded thereto with adhesive. Subsequent layers may then also be bonded to the previously applied layer using adhesive. Once sufficient layers have been applied to provide the required thickness to the body of material 12, the layer of wrapping material 13, together with the material 12 applied thereto can be formed into a hollow tubular rod by wrapping it around a mandrel, as described above. The rod is then be cut at spaced apart intervals into a plurality of individual hollow tubular components 11 for insertion of an individual tubular component into an aerosol-generating article 1.

[0081] The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only and are not exhaustive and / or exclusive.

[0082] It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised, and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropri ate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which maybe claimed in future.

Claims

Claims1. A method of manufacturing a tubular component for an aerosol-generating article for use in a non-combustible aerosol delivery system, comprising applying a flexible body of material to a layer of wrapping material and subsequently forming the layer, together with the body of material applied thereto, into a tubular component in which the body of material is encircled by said layer of wrapping material.

2. A method according to claim 1, comprising applying the body of material to said layer whilst said layer is substantially planar.

3. A method according to claim 1 or 2, comprising applying the body of material to the layer to a thickness greater than the thickness of the layer.

4. A method according to any preceding claim, comprising forming the layer, together with the body of material applied thereto, into a tubular component by wrapping said layer, together with the body of material applied thereto, around a cylindrical mandrel.

5. A method according to claim 4, wherein the method of forming the layer, together with the body of material applied thereto, into a tubular component, comprises applying adhesive to the layer so that edges of the layer that come into contact when the layer is wrapped around a cylindrical mandrel bond to each other.

6. A method according to any preceding claim, comprising attaching the body of material to the layer with adhesive.

7. A method according to any preceding claim, wherein the body of material is a non-woven sheet-like material or fibrous tow such as cellulose, and the method comprises applying said non-woven sheet-like material or fibrous tow to the layer.

8. A method according to claim 7, wherein the body of material is paper, and the method comprises applying said paper to the layer.

9. A method according to claim 8, comprising crimping or corrugating the paper prior to application to the layer.

10. A method according to any preceding claim, comprising applying the body of material to the layer of wrapping material in layers.

11. A method according to claim 10, comprising applying the layers of wrapping material to the layer consecutively.

12. A method according to claim or 11, comprising attaching the layers to each other with adhesive.

13. A method according to any of claims 1 to 5, comprising applying the body of material to the layer of wrapping material in liquid, or other non-solid phase, form and allowing it to set prior to forming the layer of wrapping material, and the body of material applied thereto, into a tubular component.

14. A method according to claim 13, comprising applying the body of material by spraying, coating or printing onto the layer of wrapping material.

15. A method according to any preceding claim, comprising applying the body of material to the layer of wrapping material in spaced elongate strips or lines so that, when the layer and the body of material applied thereto is formed into a tubular component, said elongate strips or lines extend in a longitudinal direction parallel to a longitudinal axis of the tubular component.

16. A method according to claim 15, comprising applying the body of material in spaced elongate strips or lines such that a gap is present between each strip when the layer, together with the body material applied thereto, is formed into a tubular component.

17. A method according to any of claims 1 to 15, comprising applying the body of material to the layer such that it extends continuously across the layer.

18. A method according to claim 17, comprising applying the body of material so that its thickness varies in a direction extending across the layer.

19. A method according to claim 18, comprising applying the body of material so that its thickness varies in an irregular form.

20. A method according to any preceding claim, including the step of forming an elongate rod by wrapping the layer, together with the body of material applied thereto, around a mandrel and subsequently cutting the rod to form a plurality of individual tubular components.

21. A method according to any preceding claim, wherein applying the flexible body of comprises applying a regenerated cellulose material to the layer of wrapping material.

22. A tubular component for an aerosol-generating article for use in a non- combustible aerosol-provision system, the tubular component having a longitudinal axis and comprising a body of material encircled by an outer layer of wrapping material, wherein the body of material comprises multiple layers.

23. A tubular component according to claim 22, wherein at least one layer of the multiple layers is formed from a non-woven sheet-like material or fibrous tow.

24. A tubular component according to claim 22, wherein at least one layer of the multiple layers is formed from cellulose.

25. A tubular component according to claim 22, wherein at least one layer of the multiple layers is formed from paper.

26. A tubular component according to claim 23, wherein the paper is crimped and formed from strips.

27. A tubular component according to claim 23, wherein the or each layer of the multiple layers is formed from corrugated paper.

28. A tubular component according to any of claims 21 to 25, wherein at least two of the multiple layers are attached to each other with adhesive.

29. A tubular component according to any of claims 21 to 26, wherein at least two of the multiple layers are formed from the same or different materials.

30. A tubular component according to any of claims 21 to 27, wherein the outer layer of wrapping material comprises paper.

31. A tubular component according to any of claims 21 to 29, comprising an inner layer that lines the body of material.

32. A tubular component according to claim 30, wherein the inner layer comprises paper.

33. A tubular component for an aerosol-generating article for use in a non- combustible aerosol-provision system, the tubular component having a longitudinal axis and comprising a body of material encircled by an outer layer of wrapping m aterial, wherein the body of material comprises a pl urality of l ongitudinally exten ding circumferentially spaced strips each of which extend radially inward towards the longitudinal axis.

34. A tubular component according to claim 28, wherein each strip extends parallel to said longitudinal axis.

35. A tubular component according to claim 28 or 29, wherein each strip narrows in a radially inward direction towards the longitudinal axis.

36. A tubular component according to claim 30, wherein each strip has a tip spaced from the longitudinal axis.

37. A tubular component according to claim 31, wherein each strip is shaped so that an edge of a strip, that extends between the outer layer of wrapping material and the tip, is parallel to a facing edge of an adjacent strip.

38. A tubular component according to claim 31 or 32, wherein the tip of each strip is radially closer to the longitudinal axis than to said outer layer of wTapping material.

39. A tubular component according to any of claims 31 to 33, wherein the tip of each strip comprises a surface that extends circumferentially about the longitudinal axis.

40. A tubular component according to claim 34, wherein said surface is arcuate, the axis of each surface being coaxial with the longitudinal axis of the tubular component.

41. A tubular component according to any of claims 22 to 40, wherein the body of material comprises a regenerated cellulose material.

42. An article for use in a non-combustible aerosol provision system that includes an aerosol-generating device, the article comprising a hollow tubular component made according to the method of any of claims 1 to 20.

43. An article for use in a non-combustible aerosol provision system that includes an aerosol generating device, the article comprising a tubular component according to any of claims 21 to 35.

44. A system comprising a non-combustible aerosol generating device, the aerosol generating device comprising a heating element, an aerosol-generating article according to claim 36 or 37.

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